Apparatus for making a tape carrier

ABSTRACT

Disclosed is a flexible substrate assembly including an elongated flexible substrate having a plurality of spaced apart component receiving regions, with a solid component disposed on each of said regions. A plurality of flexible strap members are disposed adjacent each component receiving region on one side thereof, and are joined to the other side of the region such that the strap overlies the region to form a tube-like passageway for receiving and containing a solid component. Several embodiments of the invention include different configurations of strap members are punched out from the flexible substrate so as to form a flap-like member having a free end, which is joined to the substrate so as to form a tube-like passageway. Also disclosed are methods for fabricating the substrate assembly and dispensing solid components contained in the substrate assemblies. Also, packaging arrangements and apparatus to produce packaging arrangements including the flexible substrate assemblies are also disclosed.

This application is a division of application Ser. No. 671,397, filedNov. 15, 1984 now abandoned.

BACKGROUND OF THE INVENTION

The present invention is directed to the packaging of solid componentsin a flexible substrate assembly having tube-like passageways eachcontaining a solid component. The present invention is also directed toan article of manufacture comprising an elongated sheet of flexiblesubstrate material, having component receiving portions for carrying aplurality of solid components, with strap-like means disposed adjacentthe component receiving portions and joined to the carrier substrate soas to form a tube-like passageway for containing a solid component. Theends of the passageways can be closed to provide a substantiallyenclosed containment of the solid components. Also, the presentinvention is directed to folding or bending the substrate assembly(having a plurality of solid components secured thereto) in aboustrophedon pattern, or winding the flexible substrate material onto areel, for transport.

The invention is also directed to a packaging system for electricalconnectors having rigid pin-like terminal means projecting therefrom.Prior to their disposition in the tube-like passageways mentioned above,the components are provided with a rigid spacer which is disposedadjacent the pin-like projections to prevent damage to those projectionsor to prevent the projections from piercing or otherwise disturbing theflexible carrier.

In the past, solid components such as electrical connectors have beenpackaged in bulk by filling a plastic bag or other suitable containerwith a number of components in contact with each other in a randommanner. However, bulk packaging is unsuitable in many applications sincethe solid components are subjected to damage during transport. Anothermore time consuming and expensive method of packaging electricalconnectors has been performed by manually aligning the connectors inlayers in a suitable container (such as a cardboard box), to minimizecontact between the connectors during storage. A layer of compressiblematerial is sometimes disposed between each layer of hand packedcomponents to minimize damage to them during transport. In yet anothermethod, solid members are disposed end-to-end in a plastic tube, butthis method is relatively expensive compared to the installed cost ofthe solid components being packaged.

The assignee of this application has described still another method inU.S. patent application Ser. No. 597,637 filed Apr. 6, 1984. In thismethod, connectors or other electrical components having a plurality ofrigid pin-like projections are mounted for transport by inserting thepin like projections in a carrier member which is typically comprised ofa polymeric foam or the like material. However, this carrier materialcomprises a porous medium which readily accepts and retains certaincontaminants which tend to deteriorate the electrical contact quality ofthe rigid pin-like projections, which comprise, for example integratedcircuit terminals.

Further, with increasing miniaturization of electrical components, andthe related to requirements of more exacting conductive properties ofelectrical terminals, insertion and withdrawal of the terminals into aporous carrier presents a significant risk of damage or deterioration tothose terminals.

Accordingly, it is an object of the present invention to provide anapparatus for making a tape-like carrier comprising a flexible substrateassembly for carrying a plurality of solid components.

These and other objects of the present invention are provided in anapparatus for making a flexible substrate assembly which includes anelongated flexible substrate having a plurality of spaced-apartcomponent-receiving regions, a plurality of solid components disposed onthe substrate, one on each region, and a plurality of pairs of alignedspaced-apart generally longitudinally extending slits, each definingflexible strap means having one end adjacent each region on one sidethereof and a second end adjacent the opposite side of said region,integrally joined by a connecting portion overlying the region to form atube-like passageway for receiving and containing the components, Theapparatus comprises a workstation whereat the assembly is made, meansfor presenting the substrate to the workstation, means for cutting thesubstrate to form the strap means, means for lifting the strap meansfrom the substrate to form a component-receiving passageway, and meansfor inserting the component between the strap means and the substrate.

In one embodiment of the present invention, the strap means is struckout from the substrate to have a free end. After the strap means islifted to allow insertion of a component thereunder, the free end isjoined to the substrate to form a tube-like passageway. In oneembodiment, the opening formed by striking out the strap means extendsalong the component-receiving passageway. In this embodiment, the strapmeans includes enlarged ear portions which are joined onto the substrateon either side of the opening. In another embodiment, the strap meanshas a free end, and is bent back to overlie a component receivingpassageway longitudinally adjacent to the opening. Again, the free endof strap means is joined to the substrate to form the tube-likepassageway.

In another embodiment of the present invention, the cutting means formsa pair of spaced-apart slits in the substrate such that the first andsecond ends of the strap means are integrally joined to the substrate.The strap lifting means is operative to displace the strap means, andthe remaining portions of the substrate laterally adjacent the slits,away from each other, to form a tube-like passageway.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other objects and advantages of the present invention willbecome apparent with reference to the drawings, with like elements arereferenced alike, wherein:

FIG. 1 is a perspective view of a flexible substrate assembly accordingto the invention, shown with an actuator arm for ejecting a solidcomponent from the substrate assembly;

FIG. 2 is a perspective view of another flexible substrate assemblyaccording to the invention shown wound about a reel for transportation;

FIGS. 3 and 4 show alternative embodiments of the flexible substrateassembly according to the present invention;

FIG. 5 is a perspective view of a flexible substrate assembly providingsubstantially enclosed containment of solid components. The substrate iswound in a boustrophedon pattern for ready storage in a box-likeshipping container;

FIG. 6 is a perspective view showing the flexible substrate assembly ofthe present invention being festooned or folded to form the continuousweb of FIG. 5;

FIGS. 7a, 7b are plan and elevation views of an apparatus for producingthe packaging arrangement of FIGS. 2-4;

FIGS. 8a, 8b are plan and elevation views of an apparatus for producingthe packaging arrangement of FIG. 1; and

FIGS. 9a, 9b show plan views of two arrangements for dispensing solidmembers contained in the packaging arrangement of FIG. 5.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Turning now to the drawings, and particularly to FIG. 1, a flexiblesubstrate assembly 10 containing a plurality of solid components such aselectrical connectors, or housings for electrical components or thelike, designated generally by reference numeral 12. Components 12 arecontained within tubular passageways 14 formed in the double layerlaminated flexible substrate carrier portion 16 of assembly 10. Carrier16 is formed of two aligned, continuous flexible sheets 18, 20 whichhave parallel overlying edges 18a, 20a and 18b, 20b. Sheets 18, 20 maybe formed of any flexible material such as mylar, polyethylene, orpolyvinyl chorlide. Sheets 18, 20 are joined to each other along seamlines 24 arranged on either side of the passageway 14. Seams 24 areformed by joining aligned pairs of opposed component receiving regionend portions using any convenient method, such as heat sealing oradhesives, but preferably by using conventional ultrasonic weldingtechniques. In its fully fabricated form, substrate assembly 10 iscomprised of an alternating series of first and second portions P1 andP2 respectively, the first component receiving portions P1 containingthe tubular passageways and the second spacer portions P2 containing theremainder of the assembly located between those passageways. Withreference to the lower substrate 20, the substrate is comprised of analternating succession of first and second portions (aligned with P1,P2, respectively) wherein components 12 are disposed on componentreceiving portions P1. The portions 18' of upper sheet 18 compriseflexible straps which are disposed adjacent portions P1 having endsjoined along seams 24 to lower sheet 20, to form the completion oftubular passageways 14. It will be readily appreciated that althoughsheet 18 is shown as having a width identical to the width of lowersheet 20, sheet 18 could be narrower than sheet 20 and could be alignedto the center or to either side of that sheet.

Also shown in FIG. 1 are actuator arms 30 which comprise, for example,armatures of solenoids 32 which are located adjacent one side ofsubstrate assembly 10. Substrate assembly 10 includes a plurality ofindexing apertures 36 which engage the teeth of a drive wheel 38, toprovide precise linear advancement of assembly 10. Apertures 36 could bereplaced by notches formed by lancing an edge of sheet 20 to formindexing flaps which are thereafter drifted to displace the flaps fromthe plane of sheet 20. Substrate assembly 10 is readily and accuratelyindexed so that tubular passageway 14 is aligned with actuator arm 30,whereupon actuator arm 30 is extended to enter passageway 14, therebydisplacing and ejecting component 12. It can be seen that thearrangement of the present invention readily provides an accurateplacement of a continuous succession of predeterminedly oriented solidmembers.

FIG. 2 shows an alternative embodiment 40 of the substrate assembly,wherein a single sheet of flexible substrate material 42 has straps 44struck out therefrom to form tubular passageways 46 for containing acontinuous succession of solid components 12. Straps 44 have a first end44a which is joined to the substrate 42 with a living hinge, and asecond free end 44b having ears 48 which are joined to substrate 42 byany suitable technique such as ultrasonic welding. As can be seen,substrate 40 is comprised of an alternating succession of firstcomponent receiving portions 50 (upon which the solid members aredisposed, and which form the lower portion of tubular passageways 46)and second spacer portions 52 which are disposed between the firstportions 50. As indicated in FIG. 2, the completed substrate assembly,with components inserted, can be wound about a reel 54, to provide aconvenient packaging assembly. When the substrate assembly is unreeledand indexed to a predetermined position adjacent a dispensing workstation, actuator arms (such as those shown in FIG. 1) can be utilizedto displace and thereby eject solid components 12 from substrateassembly 40, at the desired position.

Referring now to FIG. 3, a flexible substrate assembly 60 is showncomprising a sheet of flexible substrate material 62 from which straps64 are struck in a outward direction by a rolling cutting die or thelike conventional apparatus. Straps 64 have a first end 64a joined tosubstrate 62 with a living hinge, and a second free end 64b which, uponfolding flap 64, is joined to substrate 62 by ultrasonic welding, forexample, to form a seam 66. As can be seen in FIG. 3, flexible substrate62 comprises an alternating succession of first portions componentreceiving 70 forming a portion of tubular passageways 69, for receivingsolid members 68, and second spacer portions 72 located between thefirst portions 70. As shown in the right hand portion of FIG. 3, solidcomponent 68 comprises an electrical connector having a body 74, andplurality of outwardly extending pin-like projections 76 having freeends 78. To prevent damage or misalignment of the terminals 76 duringtransportion, and to prevent the piercing of straps 64 by thoseterminals, a rigid spacer member 80 is located adjacent terminals 76,having an upper surface 82 which projects slightly above, or is at asame level are the free ends 78 of terminal 76. When fully assembled,straps 64 will contact spacer member 80, rather than free ends 78 ofterminals 76.

Turning now to FIG. 4, a flexible substrate assembly 86 is comprised ofa flexible substrate sheet 88 from which straps 92 are formed by aplurality of spaced apart slits 94. Straps 92 have first and second ends92a, 92b joined to flexible substrate 88 to form tubular passageways 98for containing solid components 12. As can be seen in this embodiment,no ultrasonic welding or other bonding is required to join straps 92 tosubstrate 88. Also shown in FIG. 4 is a positioning work station havingactuator arms 102 which enter tubular passageways 94 to displace andthereby eject components 12 from carrier substrate assembly 86, at apredetermined location. Substrate assembly 86 has a plurality ofspaced-apart apertures or notches 104 which engage drive wheel 106 toprovide advancement of substrate assembly to a desired work station. Ascan be seen in FIG. 4, flexible substrate 88 comprises an alternatingsuccession of first component receiving portions 110 which form thelower portion of tubular passageways 94 for containing solid components12, and second spacer portions 112 located between the first portions110.

Referring now to FIG. 5, a substrate assembly 110 is shown comprising acontinuous succession of container portions 112. Substrate assembly 110is conveniently comprised of the substrate assembly 10 of FIG. 1,wherein the ends of each tubular passageway are closed by joiningadjacent edges upper and lower substrate sheets 18, 20 to form a closedend 118. In the preferred embodiment, upper and lower substrate sheets18, 20 are brought together at their ends, being ultrasonically weldedto form a seam 120 at each end of the tubular passageway.

Also shown in FIG. 5 is a packaging arrangement wherein the substrateassembly 110 is laid in a back-and-forth, boustrophedon, or festoonedarrangement, for ready containment in a box-like container 124. Thispackaging arrangement could readily accommodate the other substrateassembly embodiments described herein.

FIG. 6 shows a workstation for folding the substrate assembly 110 ofFIG. 5. The completed substrate assembly 110 has conveniently been woundonto a takeup reel 130. At folding station 132, the takeup reel 130 isdisposed on a removeable reel axis 134, so that the plurality ofsubstrate portions of predetermined length can be draped over moveablefold pins 136 disposed to overlie a rectangular slot 138 in foldingstation plate 140. The moveable fold pins 136 can be moved away from thereel 130 after the material is draped over pin 136 at regular timeintervals, to fold the substrate assembly upon itself in a boustrophedonpattern, generally designated by the numeral 125 in FIG. 5. For thispurpose, the substrate is folded such that each layer has a lengthapproximately equal to the length L of box 124 as shown in FIG. 5.

Turning now to FIGS. 7 and 8, a method and apparatus for constructingthe aforementioned flexible substrate assemblies will be shown. FIGS.7a, 7b show a work station for fabricating a flexible substrate assemblyof FIGS. 2-4. The flexible substrate assembly 42 of FIG. 2, is advancedfrom left to right in FIGS. 7a, 7b by cog drive wheels 121 which engageindexing notches or apertures formed in the substrate. As substrate 42is advanced past a rotary die unit 122, straps 44 are struck fromsubstrate 42, and upon further advancement are located adjacent aninsert station 123 where a strap lifter 125 raises strap 44 from theplane of substrate 42, to allow positioning of a component 12,therebetween. Component 12 is transported along exit track 128, byreciprocating loading arms 126. Arms 126, which grasp the connector ateither side in a vice-like fashion, are extended so as to be positionedbetween strap 44 and substrate 42. Substrate assembly 40 is thereafteradvanced such that the ears 48 are disposed between ultrasonic weldinghorn 131 and its related anvil 133 for bonding to substrate 42.

The above method and apparatus also applies to the flexible substrateassemblies shown in FIGS. 3 and 4. However, the ultrasonic weldingposition is not required for the connector assembly 86 of FIG. 4. Afterits formation in rotary die 122, the strap 92 of FIG. 4 is raised atstation 124 and solid member 100 is inserted in tubular passageway 94.

Turning now to FIGS. 8a, 8b a fabrication station similar to that ofFIGS. 7a, 7b is shown, for fabricating the flexible substrate assembly10 of FIG. 1. Upper and lower substrate sheets 18, 20 are advanced byfeed roller 137 to an insertion station 139 where solid component 12 isspatially oriented by the insertion arms 126 of a shuttle insertionmechanism, similar to that of FIGS. 7a, 7b. Thereafter, upper and lowerflexible substrate sheets 18, 20 are joined together by ultrasonicwelding horn 141, which joins a first side or tubular passageway 14.Whereafter, flexible substrate sheets 18, 20 are advanced so that theother seam 24 of tubular passageway 14 can be formed at the same weldingstation 140. Drive notches are formed in the substrate assembly atnotching die station 144 which lances and drifts the notched portions.Thereafter, flexible substrate assembly 10 is located at a pickup reelor a folding work station such as the work station 132 of FIG. 6.

Turning now to FIGS. 9a, 9b two work station embodiments for removingsolid components from the flexible substrate assembly 110 of FIG. 5 areshown. Each work station includes a drive means 152 for advancing theflexible substrate assembly 110 in predetermined amounts in thedirection of arrow 154. FIG. 9a shows notching blades 160, 162 fornotching or slitting the edges of flexible substrate assembly 110 so asto open each end 118 of containing portions 112. Thereafter, an actuatorarm 164 such as that shown in FIGS. 1, 3 or 4 can be employed to ejectcomponent 12 from the flexible substrate assembly.

FIG. 9b shows an alternative arrangement for ejecting the solid members,wherein only one side of the container is notched by notching blade 160.The opposing closed end of the container is pierced by an actuator arm168 which contains a knife blade tip 170 for slitting the upper portionof container cavity 112. As actuator arm 168 enters the containerportion 112, component 12 is displaced and thereby ejected. Analternative method of dispensing component 12 is indicated by knifeblade 174 which slits or opens one side of container portion 112 bycutting just inside the welded seam portion 24, along dotted lines 176as shown in FIG. 9b.

Although the method of forming the flexible substrate packaging assemblyhas included the formation of the flexible substrate around a spatiallypositioned component, it will be readily appreciated by those skilled inthe art that (with the exception of the substantially enclosedcontainers of FIG. 5,) the flexible substrate could be formed first,with the solid member being thereafter inserted. For example, in thearrangement of FIG. 1, flexible substrate sheets 18, 20 could be bondedtogether to form tubular passageways 14, whereupon the flexiblesubstrate carrier thus formed would be stored in a convenient manner,such as on a reel or folded in a boustrophedon pattern for storage in abox. Thereafter, the carrier assembly could be extracted and solidmembers inserted within the tubular passageways.

It will also be appreciated by those skilled in the art that therelative length of the strap and substrate first portions in each of theembodiments set forth above, need not be of equal length. For example,the straps could be longer than the first portions of the substratewhich they adjoin.

In each of the embodiments described above, the solid component can bereadily ejected from either end of the tubular passageway. This is animportant feature when the solid components having axes of symmetry thatgive the components a "reversible" configuration, depending upon the endof the component considered.

I claim:
 1. An apparatus for making a flexible substrate assembly whichincludesan elongated flexible substrate having a plurality of spacedapart component-receiving regions, a plurality of solid componentsdisposed on said substrate, one on each region, and a plurality of pairsof aligned spaced-apart generally longitudinally extending slits formedin said substrate, each defining flexible strap means having one endadjacent each region on one side thereof and a second end adjacent theopposite side of said region, integrally joined by connection portionsoverlying said regions to form a tube-like passageway for receiving andcontaining said components, the apparatus comprisinga work stationwhereat said assembly is made; means for presenting the substrate to thework station; means for cutting the substrate to form said strap means;means for lifting said strap means from said substrate to provide entryinto said component-receiving passageway; means for inserting saidcomponent between said strap means and said substrate wherein saidcutting means cuts the second end of said strap means free of saidsubstrate, said apparatus further comprising means for joining the freeend of said strap means to said substrate to form said tube-likepassageway.
 2. The apparatus of claim 1 wherein said cutting means isoperative to strike out the connecting portion of said strap means fromsaid component receiving region leaving an opening therein, with thesecond end of said strap means having a free end with laterallyextending ears; and said joining means is operable to join the ears ofsaid free end to said substrate on either side of said opening.
 3. Theapparatus of claim 1 wherein said cutting means is operative to strikeout the connecting portion of said strap means from said componentreceiving region, leaving an opening therein, and said lifting means isoperative to bend the connecting portion away from the opening, to forma tube-like passageway logitudinally adjacent said opening.